Robertshaw 712 Series Pilot Ignition Systems (Flame Rectification) User manual

Brand: Robertshaw

Model: 712 Series Pilot Ignition Systems (Flame Rectification)

Category: Fireplaces

Type: User manual

Robertshaw 712 Series Pilot Ignition Systems (Flame Rectification) provide automatic and reliable ignition for gas appliances. They are designed for use with atmospheric gas burners and are available in both lockout and non-lockout models.

Lockout models are ideal for poorly ventilated areas, as they have a safety lockout feature that prevents the system from operating for one hour if the pilot flame is not sensed after three ignition attempts. Non-lockout models are suitable for well-ventilated areas and offer continuous ignition attempts until the pilot flame is established.

The 712 Series Pilot Ignition Systems are CSA design certified to applicable ANSI standards and feature:

INSTALLATION DATA

712 SerieS Pilot

ignition SyStemS

(FlAme reCtiFiCAtion)

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712-022

CSA DESIGN CERTIFIED TO APPLICABLE A.N.S.I. STANDARD



Robertshaw 1-963 Rev D.indd 1 11/3/14 3:32 PM

ORDERING DATA

ORDER NUMBER

GAS VALVE

CONNECTION

IGNITION UNIT MODEL - GAS DESCRIPTION



712-005

722-079

1/2" x 1/2"

780-845

(Lockout)

Universal Model- Gas valve has natural gas pressure

regulator set at 3.5" WC. A separate LP gas pressure

regulator set at 11.0" WC is also included. 170,000 BTU

Max. Nat. Gas/272,000 BTU Max. LP gas.

712-006

700-056

3/4" x 3/4"

780-845

(Lockout)

Universal Model - Gas valve has natural gas pressure

regulator set at 3.5" WC. A separate LP gas pressure

regulator set at 11.0" WC is also included. 350,000 BTU

Max. Nat. Gas/560,000 BTU Max. LP gas.

712-008

720-070

1/2" x 3/4"

780-845

(Lockout)

Universal Model - Gas valve has natural gas pressure

regulator set at 3.5" WC. A separate LP gas pressure

regulator set at 11.0" WC is also included. 200,000 BTU

Max. Nat. Gas/320,000 BTU Max. LP gas.

712-009

700-059

1" x 1"

780-845

(Lockout)

Universal Model - Gas valve has natural gas pressure

regulator set at 4.0" WC. A separate LP gas pressure

regulator set at 11.0" WC is also included. 720,000 BTU

Max. Nat. Gas/1,152,000 BTU Max. LP gas.

Non-lockout Models - Caution: Do Not Use On LP Gas Applications

712-015

720-072

1/2" x 3/4"

780-715

(Non-lockout)

Natural Gas Only - Non-lockout. Valve has 1/2" side outlets.

Pressure regulator is factory-set at 3.5" WC 200,000 BTU

Max.

712-016

700-056

3/4" x 3/4"

780-715

(Non-lockout)

Natural Gas Only - Non-lockout. Pressure regulator is

factory-set at 3.5" WC 350,000 BTU Max.

712-017

720-070

1/2" x 3/4"

780-715

(Non-lockout)

Natural Gas Only - Non-lockout. Pressure regulator is

factory-set at 3.5" WC 200,000 BTU Max.

712-019

700-059

1" x 1"

780-715

(Non-lockout)

Natural Gas Only - Non-lockout. Pressure regulator is

factory-set at 4.0" WC 720,000 BTU Max.

712-022

722-079

1/2" x 1/2"

780-715

(Non-lockout)

Natural Gas Only - Non-lockout. Pressure regulator is

factory-set at 3.5" WC 170,000 BTU Max.

*The 780-845 lockout ignition control used in the 712 series Kits, provides 90 seconds of spark followed by a six minute

time delay (purge) period between ignition attempts. After three tries, if no pilot ame is sensed, 780-845 goes into a 1 hour

lockout period. At the end of the 1-hour lockout period, if the demand for heat is still present, unit repeats the three tries for

ignition.

Robertshaw 1-963 Rev D.indd 2 11/3/14 3:32 PM

SPECIFICATIONS

GAS VALVES

The Robertshaw

gas valves used in the 712 Series kits are CSA design certified to applicable ANSI standards. Gas valves

that are included in the 712 Series pilot ignition systems have a built-in, slow-opening feature for soft ignition characteristics

at the main burner. Does not include the 712-005 and 712-022 kits.



Electrical 24 volt, 60 Hz

Ambient rating - 40°F to 175°F

(- 40°C to 80°C)

Capacity (maximum regulation)

1/2" x 3/4" straight-through 300,000 BTU

3/4" x 3/4" straight-through 350,000 BTU

Pressure regulator (factory-set) 3.5" WC Natural Gas

(Adjustable 3" to 7" WC)



Electrical 24 volt, 60 Hz

Ambient rating - 40°F to 175°F

(- 40°C to 80°C)

Capacity (maximum regulation)

1" x 1" 720,000 BTU

3/4" x 1" using reducer bushings

(included)

530,000 BTU

3/4" x 3/4" using reducer bushings

(included)

450,000 BTU

Pressure regulator (factory-set) 4.0" WC Natural Gas

(Adjustable 3" to 7" WC)

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Electrical 24 volt, 60 Hz

Ambient rating - 40°F to 175°F

(- 40°C to 80°C)

Capacity (maximum regulation)

1/2" x 3/4" straight-through 200,000 BTU

Pressure regulator (factory-set) 3.5" WC Natural Gas

(Adjustable 3" to 7" WC)

11.0" WC LP Gas (Adjustable 8"

to 12" WC)

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Electrical 24 volt, 60 Hz

Ambient rating - 40°F to 175°F

(- 40°C to 80°C)

Capacity (maximum regulation)

1/2" x 1/2" straight-through 170,000 BTU

Pressure regulator (factory-set) 3.5" WC Natural Gas

Input voltage 24 VAC 50/60 Hz

Transformer 24 VAC / 20 VA minimum

Robertshaw 1-963 Rev D.indd 3 11/3/14 3:32 PM

IGNITION CONTROL UNITS

Robertshaw ignition control units used in the 712 Series kits are CSA design certified to applicable ANSI standards.



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Safety lockout timing (780-845) See footnote*

Spark rate 3 to 4 sparks per second

Relay contact ratings

Pilot valve 1 amp at .5 PF

Main valve 1 amp at .5 PF

Combined load 1.5 at .4 PF

Flame sense current .7 µA DC @ 25°C / 24 VAC

Maximum total current load 1.5 amp

Flame failure re-ignition time .8 seconds maximum

Thermostat anticipator setting .7 amp

Ambient rating - 40°F to 175°F

(- 40°C to 80°C)

Relative humidity 95% non-condensing at 104°F

*The 780-845 lockout ignition control used in the 712 series kits, provides 90 seconds of spark followed by a six minute time

delay (purge) period between ignition attempts. After three tries, if no pilot ame is sensed, the 780-845 goes into a 1 hour

lockout period. At the end of the 1 hour lockout period, if the demand for heat is still present, the unit repeats the three tries

for ignition.

PRE-INSTALLATION INSTRUCTIONS

780-715

780-845

CAUTION

The 712 Series Pilot Ignition System must be installed

by a qualified installing agency with due regard for

safety. Improper installation could result in a hazardous

condition.

Installation must comply with all local codes. In the

absence of local codes, the latest edition of the National

Fuel Gas Code, ANSI Z223, and the National Electrical

Code ANSl/NFPA No. 70 must be used.

The 712 Series Pilot Ignition System has been designed

for an easy installation, however, for the system to

function properly and to give trouble-free service. The

installer must follow these installation instructions word

for word and without taking any short cuts. Take your

time installing this system, make sure it is working

properly before leaving the job site. Failure to do so could

result in a system failure.

This Pilot Ignition System must be used only on

appliances equipped with an atmospheric gas burner.

Use on direct-vent type appliances and power burners is

prohibited.

Be sure you have the correct Pilot Ignition System for the

type of gas used on the application, LP or natural. Using

an incorrect system could result in a hazardous condition.

LP Gas Application

Use the lockout models only for inside or poorly

ventilated applications.

Natural Gas Application

Use either model type: Lockout models 712-005, 712-006,

712-008, 712-009 or non-lockout models 712-015, 712-016,

712-017, 712-019, 712-022.

Ambient Temperature Limitations

Be sure the installation of the Pilot Ignition System will

not exceed its rated ambient temperature range: -40°F to

175°F (-40°C to 80°C). This is extremely important when the

application is being made to a rooftop unit in cold climates.

SAFETY INSPECTION PROCEDURES

The CSA pre-installation safety procedures listed below are

intended as a guide to aid in determining that an appliance is

properly installed and is in a safe condition for continued use.

This procedure is predicated on central furnace and boiler

installations equipped with an atmospheric gas burner(s)

and not at the direct-vent type. It should be recognized that

generalized test procedures cannot anticipate all situations.

Accordingly, in some cases, deviation from this procedure

may be necessary to determine safe operation of the

equipment.

A. This procedure should be performed prior to any

attempt at modification of the appliance or

the installation.

Robertshaw 1-963 Rev D.indd 4 11/3/14 3:32 PM

B. If it is determined there is a condition which could

result in unsafe operation, the appliance should be

shut off and the owner advised of the

unsafe condition.

The following steps should be followed in making the safety

inspection:

1. Conduct a gas leakage test of the appliance piping and

control system downstream of the shutoff valve in the

supply line to the appliance.

2. Visually inspect the venting system for proper size and

horizontal pitch and determine that there is no blockage

or restrictions, leakage or corrosion or other deficiencies

which could cause an unsafe condition.

3. All gas equipment must have an accessible manual gas

shutoff valve installed in the gas supply line upstream of

the appliance. If a manual, accessible gas valve is not in

the gas supply line within six feet of the appliance, one

shall be installed. Shut off all gas to the appliance and

shut off any other fuel burning appliance in the same

room. Use the shutoff valve in the supply line to

each appliance.

4. Inspect burners and crossovers for blockage and

corrosion. Inspect all wiring for damage, correct any

defects found.

5. Applicable only to warm air heating appliances. Inspect

heat exchangers for cracks, openings or

excessive corrosion.

6. Applicable only to boilers. Inspect for evidence of water

or combustion product leaks.

7. As far as is practical, close all building doors and

windows and all doors between the space in which the

appliance is located and other spaces of the building.

Turn on clothes dryers. Turn on any exhaust fans, such

as range hoods and bathroom exhausts, so they will

operate at maximum speed. Do not operate a summer

exhaust fan. Close fireplace dampers. If after completing

steps 7 through 12, it is believed sufficient combustion

air is not available, refer to 1.3.4 National Fuel Gas Code

(2223.1) for guidance.

8. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance

will operate continuously.

A. Determine that the pilot is burning properly and that

main burner ignition is satisfactory by interrupting

and re-establishing the electrical supply to the

appliance in any convenient manner.

B. With a manometer, determine manifold pressure in

order to match input after the new control is installed.

10.

A. Visually determine that main burner gas is burning

properly; i.e., no floating, lifting or flashback. Adjust

the primary air shutter(s) as required.

B. If appliance is equipped with high and low flame

control or flame modulation, check for proper main

burner operation at low flame.

11. Test for spillage at the draft hood relief opening after

5 minutes of main burner operations. Use a draft

gauge, the flame of a match or candle, or smoke from a

cigarette, cigar or pipe.

12. Return doors, windows, exhaust fans, fireplace dampers

and all other fuel-burning appliances to their previous

conditions of use.

13. Applicable only to warm air heating appliances: Check

both limit control and fan control for proper operation.

Limit control operation can be checked by temporarily

disconnecting the electrical supply to the blower motor

and determining that the limit control acts to shut off the

main burner gas.

14. Applicable only to boilers:

A. Determine that the circulating water pumps are in

operating condition.

B. Test low water cutoffs, automatic feed water

controls, pressure and temperature limit controls and

relief valves in accordance with the manufacturer's

recommendations and instructions to determine that

they are in good operating condition.

TESTING THE EXISTING SYSTEM

Before starting installation, a safety inspection of the

appliance must be performed. Once safety inspection has

been completed, continue as follows:

1. Check that the existing pilot is a thermocouple type used

with an electromagnetic safety. Some manufacturers

use bimetal type pilots wired to the valve operator. If the

application has a bimetal pilot, it must be replaced with a

thermocouple-type pilot.

2. The Pilot Ignition System is designed to be adapted to

the existing pilot.

NOTE: Robertshaw and CSA recommend that the original

pilot be used and remain in its original position.

3. Locate the rating plate on the appliance and determine

the input rating (BTU per hour). The input rating

(capacity) for the Pilot Ignition System must be equal

to or greater than the input rating of the appliance. See

SPECIFICATIONS for Pilot Ignition System Capacity or

Input Rating.

4. Do not install in a wet area without protection for

the components.

5. To ensure proper operation, the appliance transformer

must be rated at:

24 volts/20VA (minimum)

24 volts/40VA (minimum) - When used in conjunction

with an Automatic Vent Damper.

The output of the appliances transformer can be

determined by the following steps:

A. Compute the total current draw by adding the

current draw of the Pilot Ignition System (.7 amp) to

the current draw of any associated valving, relays,

dampers or other devices operated by

the transformer.

Robertshaw 1-963 Rev D.indd 5 11/3/14 3:32 PM

B. Multiply the total current draw computed in "A" above

by 24 volts. This will give the total VA (Voltage-

Amperage) required.

C. The total VA (Volt-Amperage) required should be

equal to or less than the VA rating of the

appliance transformer.

D. If the total VA (Volt-Amperage) required is greater

than the VA rating of the transformer, replace it with

a Class 2 transformer of adequate rating.

6. Cycle the furnace ON to ensure it is working properly. If

the transformer, limit switch or thermostat are faulty, the

ignition system will not function. Check the performance

characteristics of the pilot flame. The flame should be

impinging on the thermocouple and be blue in color. If

not, you will need to adjust the pilot and/or clean the

orifice and pilot tube. Be sure that inlet gas pressure

is adequate.

7. Turn OFF all electrical power and gas to the appliance

before attempting to disconnect the wiring and gas valve.

To shut off the gas, use the shutoff valve in the supply

line to the appliance. If a manual gas valve is not in the

gas supply line within 6 feet of the appliance, and in an

accessible location, one shall be installed. DO NOT USE

THE GAS COCK ON THE GAS VALVE.

8. Remove the thermocouple and pilot tubing from the

existing gas valve.

9. You may encounter two methods of gas valve wiring.

Determine from the diagrams below which one you have.

Disconnect the electrical leads from the gas valve.

A. TWO TERMINAL CONNECTION

Disconnect the two wires connecting the gas valve.

B. THREE TERMINAL CONNECTION

If three terminals on the gas valve are used, two

wires may be connected to a common terminal.

Remove these two wires first and wire-nut them

together. Three wire nuts are provided in the kit.

Now, remove the other two wires from the existing

gas valve.

10. Remove gas valve and/or controls containing the main

valve, regulator and safety functions from the manifold.

These functions are built into the new replacement

gas valve.

11. Remove the pilot assembly and disconnect the

thermocouple from the pilot. The pilot will be reinstalled

back into its original mounting position.

12. Inspect the inside of the pilot tubing. It should be free

of any scale or other foreign matter. Clean or replace if

necessary. We also recommend that the pilot orifice be

cleaned to ensure optimum system operation.

INSTALLATION INSTRUCTIONS

IGNITOR/SENSOR ASSEMBLY

NOTE: On some pilot applications a special adaptor kit is

required. These adaptor kits are shown on page

8. Order these pilot adaptor kits separately

if needed.

1. Assemble the combination ignitor/sensor assembly by

sliding the mounting bolt through the mounting bracket

as shown in Figure 1.

Figure 1

2. The ignitor/sensor assembly is ready to be attached to

the furnace pilot. Slide the mounting bolt with the ignitor/

sensor bracket down through the thermocouple opening

of the pilot frame as shown in Figure 2. Install the

retainer nut onto the mounting bolt and tighten

finger tight.

Figure 2

3. The ignitor/sensor can now be positioned for proper

sparking and sensing. To obtain the best ignition

characteristics:

• The ignitor/sensor tip should be located on a

horizontal plane with the top of the pilot gas exit port.

• The tip should be located 1/8" (recommended spark

gap) from the edge of the pilot hood.

Robertshaw 1-963 Rev D.indd 6 11/3/14 3:32 PM

Figure 6

B. Measure down the ignitor/sensor rod this distance

plus 1/16" to allow for bend radius Figure 7. DO

NOT BEND YET.

Ceramic Insulator

Figure 7

7. Holding pliers firmly on the ignitor/sensor rod at the

distance measured, use finger pressure on the ignitor/

sensor rod tip to slowly bend it towards pilot hood,

Figure 8. If tip is too long, cut off excess.

Figure 8

NOTE: lgnitor/sensor tip must be in pilot flame for the Ignition

Control Unit to function properly.

8. Reinstall pilot assembly back into its original mounting

position.

• Be sure that sparking will occur in the path of the

gas flow.

• Excess "wire or rod" should be cut off.

• Tighten the mounting bolt firmly so that the bracket

assembly will not move or change position once the

pilot is installed. See Figure 3.

Figure 3

4. Bend the tabs to the ignitor/sensor mounting bracket

down and around the pilot bracket frame. Using a pair of

pliers, crimp the tabs so they grip the pilot bracket. This

will hold the electrode assembly firmly in place as shown

in Figure 4.

Figure 4

5. When selecting the ignitor/sensor tip location, remember

the spark will jump the narrowest gap available to the

nearest ground metal. Ensure that this gap is always at

the point you select and not to the main burner, furnace

chassis, burner manifold, or a part of the pilot hood

where there is no flow, see Figure 5. The tip must be in

the pilot flame for the ignitor/sensor to function properly.

Bend Tabs Down

Figure 5

6. After crimping the ignitor/sensor mounting bracket tabs

and selecting the point for the ignitor/sensor tip to spark to:

A. Measure the distance from this point to the ignitor/

sensor rod Figure 6.

CAUTION

Always hold the ignitor/sensor rod between the

ceramic and the bend you are making. This will



must not contact the ceramic portion of the ignitor/

sensor assembly.

Robertshaw 1-963 Rev D.indd 7 11/3/14 3:33 PM

NOTE: Pilot is not to be relocated or altered. If replacing the

pilot becomes necessary due to wear or damage, an

exact replacement must be used.

SPECIAL PILOT ADAPTOR KITS

These special pilot adaptor kits are NOT included in the 712

kits. They must be ordered separately.



PILOT ADAPTOR KIT

Includes all the necessary parts to

adapt the Magic Chef, Gaffers & Sattler

sheet metal pilot to the 712 Series

flame rectification pilot system.

ORDER 1751-712

INSTALLING THE GAS VALVE

• Installation and servicing of gas appliances and

ignition systems must only be performed by

qualified personnel.

• Turn off gas and electricity before starting installation

or service.

• When replacing an LP control or a natural gas

control, the new control must have the same

regulator setting as the old control, or as specified

on the appliance rating plate.

• To install or remove the control, use the inlet boss as

a gripping location to prevent unwanted rotation. Do

not grip body with pipe wrench or vise.

• Make sure gas piping is pressure tested before

control is connected. High pressure can damage the

control causing a hazardous condition.

• Make sure piping is clean and free from burrs.

Apply a small amount of good quality pipe thread

compound or plumbers tape suitable for the gas

being used. Thread compound should be used

sparingly on male threads only, leaving the first two

threads clean.

1. Install the gas valve so gas flow conforms with the inlet

gas flow indicated on the valve body. A wrench should

only be used on flat surfaces of the inlet boss. Never use

a wrench on the body of the valve as this may distort

the casting.

2. A sediment trap must be present in the gas supply line.

If one is not present one must be installed to prevent dirt

from entering the control. See Figure 9. All piping must

conform to local codes and ordinances and with National

Gas Codes (ANSI Z223.1 and NFPA No. 54).

Figure 9

3. The valve should be mounted with the wiring terminals

at the top for easy access in installation of wiring and

fixture service testing.

WARNING: Do not mount valves upside down.

4. Connect the pilot tubing to the pilot gas outlet. Use the

fitting provided and tighten for gas seal. Do not bend the

tubing after tightening.

NOTE: Valves have a built-in vent limiter. The regulator vent

is tapped so a tubing adaptor can be installed if vent

tubing is required by local codes.

All components must be securely mounted with screws, bolts

etc., within the appliance.

WIRING THE IGNITION CONTROL UNIT

1. Wiring must conform to local codes and ordinances. A

high limit switch is required in either the 120V or 24V

side of the transformer.

2. Make certain all wiring connections are tight.

3. The 712 series pilot ignition kits include a six-wire (blue)

harness assembly. This harness assembly connects the

gas valve to the ignition control unit. To wire the ignition

control unit:

A. Attach blue wire to terminal "PV" (pilot valve,

pilot gas).

B. Attach red wire to terminal "MV" (main valve,

main burner).

C. Attach gray wire to terminal "TH" (thermostat).

D. Attach green wire to "GND" terminal.

E. Attach black/white wire to terminal

"MV/PV" (common).

NOTE: The white and black wires are assembled into one

quick-connect terminal and it is normally attached to

the MV/PV terminal. However, the GND, MV/PV and

TR terminals are electrically identical, and the green,

white and black wires may be attached to any of

these terminals.

4. If the appliance has an automatic vent damper, verify

that damper is in the full open position. We recommend

that the 712 series kit be installed and tested as

instructed in SYSTEM CHECKOUT PROCEDURES prior

to connecting the vent damper into the system.

5. Locate ground terminal connector.

WARNING: Gas valve must be grounded to prevent

burnout of gas valve terminal circuit board.

A. The 7000 Series Gas Valve is included in the

following kits: 712-006, -009, -016 and -019. Attach

ground terminal connector to the top of the

gas valve.

CAUTION





clogging of the tubing and improper regulator operation. If



shielded from moisture.



may clog and cause gas valve to malfunction.

Robertshaw 1-963 Rev D.indd 8 11/3/14 3:33 PM

B. The 7200 Series Gas Valve is included in the

following kits: 712-008 ,-015 and -017. Attach the

grounding terminal to the gas valve.

C. The 2000 Series Gas Valve is included in the

following kits: 712-005 and 712-022. Attach the green

ground wire in the wiring harness to the terminal on

the gas valve.

Grounding Terminal

Figure 10

6. Locate the green wire in the six-wire harness. Be sure

that this wire is connected to the GND terminal on the

ignition unit and to the gas valve - see page 10.

7. Locate the separate ground wire included in the 712 kit.

Connect the "ring" terminal to the mounting screw that

attaches the pilot assembly to the furnace. Connect the

other end to the "TR" terminal on the ignition control unit.

8. The six-wire harness is used to connect the ignition

control unit to the gas valve and to the thermostat control

circuit. Determine which gas valve type you have (7000,

7200 or 2000) and proceed as directed by the

following instructions.

9. Some appliance wiring may result in one terminal of the

secondary side of the transformer being grounded. If this

condition exists, damage to the transformer may occur if

the two wires (black and gray) in the wiring harness are

connected improperly to the two wires removed from the

old gas valve. It is necessary to determine which wire is

grounded before proper connection to the wiring harness

can be made.

A. Be sure all gas to the appliance is turned off. Make

sure the two wires removed from the old gas valve

will not touch the furnace chassis or each other.

B. Turn on the electrical power to the furnace and set

the thermostat to the high setting.

C. Set the test meter to the 24 volt AC scale. Touch or

clamp one meter probe to the chassis of the furnace.

D. Touch the other probe of the meter to each wire, one

at a time.

E. If no meter reading is obtained, the two wires

removed from the old gas valve may be connected

to either wire (black or gray) in the new wiring

harness.

If a 24 volt reading is obtained at one wire, that wire

must be connected to the gray wire in the wiring

harness.

Robertshaw 1-963 Rev D.indd 9 11/3/14 3:33 PM

7000 SERIES GAS VALVES

When installing kit numbers 712-006, -009, -016, and -019,

refer to the wiring diagrams shown below. This illustrates

the wiring method when using a 7000 series gas valve. The

wiring connections at the gas valve are as follows:

1. Locate the 4" white jumper wire in the kit.

2. Attach one end (quick-connect) to one terminal of

the solenoid valve. Attach the other end to the screw

terminal "TR" on the gas valve operator.

3. Connect the white wire in the wiring harness to the quick

connect terminal at "TR".

4. Connect the red wire to the "TH" terminal on the gas

valve.

5. Attach the blue wire which has a non-insulated

connector to the solenoid pilot valve.

6. Attach green wire to the ground terminal on the gas

valve.

7. Connect the wire from the pilot ignitor/sensor to the

"IGN" terminal on the ignition control unit.

8. With all wiring completed to this point, return to step 9

in the WIRING THE IGNITION CONTROL UNIT section

and proceed as directed.

Robertshaw 1-963 Rev D.indd 10 11/3/14 3:33 PM

7200 SERIES GAS VALVES

When installing kit numbers 712-008, 712-015, and 712-017,

refer to the diagrams shown below. This illustrates the wiring

method when using a 7200 series gas valve. The wiring

connections at the gas valve are as follows:

1. Attach the blue wire which has a non-insulated

connector to terminal "P" on the gas valve connector.

2. Attach the white wire to terminal "C".

3. Attach the red wire to terminal "M".

4. Attach green wire to the ground terminal.

5. Connect the wire from the pilot ignitor/sensor to the

"IGN" terminal on the ignition control unit.

6. With all wiring completed to this point, return to step 9

in the WIRING THE IGNITION CONTROL UNIT section

and proceed as directed.

Robertshaw 1-963 Rev D.indd 11 11/3/14 3:33 PM

2000 SERIES GAS VALVES

When installing kit numbers 712-005 and 712-022, refer

to the diagrams shown below. This illustrates the wiring

method when using a 2000 series gas valve. The gas valve

connections are made by a plug-in terminal.

1. Attach green wire to ground terminal.

2. Connect the wire from the pilot ignitor/sensor to the

"IGN" terminal on the ignition control unit.

3. With all wiring completed to this point, return to step 9

in the WIRING THE IGNITION CONTROL UNIT section

and proceed as directed.

Robertshaw 1-963 Rev D.indd 12 11/3/14 3:33 PM

SYSTEM CHECKOUT

PROCEDURES

The initial installation portion is now completed. The

checkout procedures listed below must be followed. While

there are redundant safety features built into the system, it is

imperative that you follow the steps outlined below to ensure

proper and safe operation. If you encounter any irregularities,

refer to the TROUBLESHOOTING GUIDE.

1. Check all wiring connections.

2. Turn on main gas supply and put the manual valve or

selector arm on the gas valve into the "ON" position.

3. Use a leak test solution to check piping for gas leaks.

Repair if needed.

4. Turn on electrical power.

5. Set thermostat to high.

WARNING: Vent damper must be in the fully open

position before the ignition system is

energized. Failure to verify this may cause a

serious health hazard to occupants.

6. Sparking begins, pilot gas ignites.

7. Pilot flame on ignitor/sensor, main burner on.

8. If the ignition control unit is a 780-715, with main burner

on, cycle thermostat off then on. System will turn off and

immediately on again.

9. With the main burner on, turn the manual gas valve to

off position. Wait until all flame is out. Turn manual gas

valve on again.

A. Sparking will begin as soon as the pilot flame is out.

B. Pilot ignition takes place when gas flow is restored.

10. 

With the main burner on, turn the manual gas valve

off. Sparking will begin when the pilot flame goes out.

After 90 seconds the system will go into time delay (6

minutes) and sparking will cease. The lockout ignition

control used provides 90 seconds of spark followed by

a six minute time delay (purge) period between ignition

attempts. After three tries, if no pilot flame is sensed, a

1-hour lockout period will begin. At the end of the 1-hour

lockout period, if the demand for heat is still present, unit

repeats the three tries for ignition.

11. Check manifold pressure and compare the reading with

those obtained in the PRE-INSTALLATION - SAFETY

INSPECTION PROCEDURES. Adjust pressure regulator

(if necessary) to match the original input.

12. Visually determine that the main burner is burning

properly, as it was during the PRE-INSTALLATION -

SAFETY INSPECTION PROCEDURES; i.e., no floating,

lifting, or flashback. Adjust the primary air shutter(s)

as required.

13. It is absolutely necessary that the system be cycled

normally (thermostatically controlled) through at least

three complete heating cycles. Set thermostat to a

temperature slightly higher (at least 5°) than the existing

ambient. Allow the appliance to cycle ON and run

through a normal cycle. Do not manually shorten

the cycle.

14. Applicable only to furnaces: Check both the limit

control and the fan control for proper operation. Limit

control operation can be checked by blocking the

circulating air inlet or temporarily disconnecting the

electrical supply to blower motor. Determine that the limit

control acts to shut off the main burner gas.

Applicable only to boilers: Determine that the circulating

water pumps are in operating condition. Test low

water cutoffs, automatic feed controls, pressure

and temperature limit controls, and relief valves in

accordance with the manufacturer's recommendation to

determine they are in operating condition.

15. The initial checkout procedures have been completed.

If the system has functioned normally, return thermostat

setting to its normal setting. The qualified installing

agency must completely fill out and apply the yellow

appliance conversion sticker to the front of the appliance.

Leave these and all other instructions with

the homeowner.

Robertshaw 1-963 Rev D.indd 13 11/3/14 3:33 PM

TROUBLESHOOTING GUIDE

PILOT IGNITION SYSTEM / FLAME

RECTIFICATION / IGNITION CONTROL



There are five potential problem conditions with the

thermostat set high.

To perform the following test you will need a volt /ohmmeter.

Refer to your appropriate wiring diagrams.

The ignition control can also be tested, using the Robertshaw

ignition control tester, part number 900-575.



gas.

Possible Causes:

A. No main power

B. Faulty transformer

C. Faulty thermostat

D. Faulty limit

E. Faulty ignition control unit

Solution:

1. With power on and thermostat set high, set your test

meter to the 24 volt scale. Probe terminals TH and TR. If

you do not read 24 volts, the problem is not the ignition

system. Perform normal system checks of main power,

transformer, thermostat and the limit control. If you do

read 24 volts at TH and TR the problem is in the ignition

system. Check for loose or defective wiring. If wiring is

good replace the ignition control unit.



Possible Causes:

A. Main gas supply turned off

B. Manual valve on gas valve turned off

C. Faulty primary valve in the gas valve

D. Faulty wire connection

E. Faulty ignition control unit

Solution: Set test meter to 24 volt scale.

1. Be sure main gas valve (gas cock or selector arm) is

turned on.

2. With gas on and the system sparking, probe terminals

PV and TR. If 24 volts is read at these terminals and

pilot gas does not flow, replace the gas valve.

3. If you do not read 24 volts at terminals PV and

MV/PV replace the ignition control unit.



Possible Causes:

A. Defective ignitor/sensor and/or its wiring

B. Faulty ignition control unit

Solution: Set test meter to ohm scale.

1. Disconnect the wire from the IGN terminal on the ignition

control unit.

2. Touch one meter probe to the tip of the ignitor/sensor

rod in the pilot. Touch the other probe to the quick-

connect at the other end of the ignitor/sensor wire.

3. If you have continuity from the tip of the

ignitor/sensor rod to the connector and no spark, replace

the ignition control unit.

4. If you do not have continuity through the wire and the

ignitor/sensor, check for loose wire connection in the

wire. Repair as needed.

5. Check to see if spark shorts to furnace through a cut in

the ignitor wire.



not turn on.

Possible Causes:

A. Faulty main valve coil in the gas valve

B. Faulty ignitor/sensor and/or its wiring

C. Ground wire not attached to furnace chassis

D. Flame rectification signal from pilot to ignition control

unit weak

E. Faulty ignition control unit

Solution: Set test meter to 24 volt scale.

1. With pilot flame on ignitor/sensor - probe terminals MV

and MV/PV on the ignition control unit. If you read 24

volts here, but not at the gas valve, there is a loose

wiring connection. Repair or replace as needed.

2. If you do read 24 volts at MV and MV/PV and the pilot

flame is impinging on the ignitor/sensor rod, the problem

may be:

• Faulty ignitor/sensor and/or its wiring

• Faulty ignition control unit

• No flame rectification signal to ignition control unit.

3. Set test meter to the ohm scale. Set thermostat low-

system off.

4. Check continuity through the green ground wire between

the pilot mounting bracket and the ignition control unit.

Repair or replace as needed.

5. Check continuity through the green ground wire between

the gas valve and the ignition control unit. Repair or

replace as needed.

6. Check ignitor/sensor for continuity, through the spark/

sensor rod. Also, check ignitor/sensor ceramic for

cracks. Repair or replace as needed.

7. Reconnect all wires that were disconnected, including

the ignitor/ sensor wire and the ground wire.

8. Set thermostat high. With the pilot burning and the flame

on the ignitor/sensor rod, if the main burner does not

turn on - replace the ignition control unit.

Robertshaw 1-963 Rev D.indd 14 11/3/14 3:33 PM

Problem #5: Short-cycling of main burner.

Main burner turns off before the thermostat



Possible Causes:

A. Draft condition pulls pilot flame away from ignitor/

sensor rod

B. Incorrect thermostat anticipator setting

C. Pilot flame gets smaller when main burner

comes on.

D. Faulty limit control

Solution:

1. Check the thermostat anticipator setting. Set to .7 amp.

A lower setting will cause short-cycling.

2. Set thermostat high, with main burner on, observe the

pilot flame impingement on the ignitor/sensor rod.

• If pilot flame is small and draft condition pulls flame

from ignitor/sensor rod the burner will turn off and

then on again.

• Adjust pilot flame higher or clean pilot orifice.

• Bend ignitor/sensor rod closer to pilot flame .

3. If flame impingement on the ignitor/sensor is stable and

the system short-cycles, check the limit switch.

4. Set test meter to 110 volt scale.

• When the system cycles off, probe the switch

terminals of the limit switch.

• If you read 110V or 24V across the switch terminals

the limit switch is open. Replace the limit switch.

5. A pilot flame set too high will also cause burner to short

cycle. Pilot flame lifts over ignitor/sensor.

Robertshaw 1-963 Rev D.indd 15 11/3/14 3:33 PM

Customer Service Telephone 1.800.304.6563

Customer Service Facsimile 1.800.426.0804

[email protected]

Robertshaw

, Ranco

®,

Paragon

and Uni-Line

is a trademark

of Robertshaw its subsidiaries and/or affiliated companies.

All other brands mentioned may be the trademarks of their

respective owners.

For Technical Service

Telephone 1.800.445.8299

Facsimile 1.630.260.7294

[email protected]

www.Uni-Line.com

www.Robertshaw.com

10/14 - 1-963 Rev D

Robertshaw 1-963 Rev D.indd 16 11/3/14 3:33 PM

Robertshaw 712 Series Pilot Ignition Systems (Flame Rectification) User manual

Brand: Robertshaw

Model: 712 Series Pilot Ignition Systems (Flame Rectification)

Category: Fireplaces

Type: User manual

The 712 Series Pilot Ignition Systems are CSA design certified to applicable ANSI standards and feature:

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Robertshaw 712 Series Pilot Ignition Systems (Flame Rectification) User manual

Robertshaw 712 Series Pilot Ignition Systems (Flame Rectification) User manual

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